Acoustic ceiling board with improved aesthetics

Patent metadata

Field	Value
Publication number	US-2016138264-A1
Application number	US-201615006989-A
Country	US
Kind code	A1
Filing date	Jan 26, 2016
Priority date	May 16, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

Described herein are acoustical panels comprising a substrate and a coated non-woven veil that comprises a coating applied to a non-woven veil, the non-woven veil having an airflow resistance of greater than 45 mks rayls and comprising: from about 20 wt. % to about 60 wt. % fibers; and from about 40 wt. % to about 80 wt. % of a filler; and wherein the coating is present on the non-woven veil in an amount ranging from about 110 dry g/m 2 to about 135 dry g/m 2 . Methods of making and using the panels are also described.

First claim

1 . An acoustical panel, comprising:
a substrate; a coated non-woven veil comprising a coating applied to a non-woven veil, the non- woven veil having an airflow resistance of greater than 45 mks rayls and comprising:
from about 20 wt. % to about 60 wt. % fibers; and
from about 40 wt. % to about 80 wt. % of a filler; and
wherein the coating is present on the non-woven veil in an amount ranging from about 110 dry g/m 2 to about 135 dry g/m 2 .

2 . The panel of claim 1 , wherein the non-woven veil demonstrates a hiding power value of greater than 75%.

3 . The panel of claim 1 , wherein the coated non-woven veil has an airflow resistance of about 300 mks rayls or less.

4 . The panel of claim 1 , wherein the filler comprises aluminum trihydrate.

5 . The panel of claim 1 , comprising about 120 dry g/m 2 of the coating.

6 . The panel of claim 1 , wherein the coating is not continuous.

7 . The panel of claim 1 , wherein the coating comprises a binder and particles.

8 . The panel of claim 7 , wherein the particles have a d 50 of from about 50 microns to about 300 microns.

9 . The panel of claim 1 , wherein the non-woven veil is affixed to the substrate using an adhesive.

10 . The panel of claim 9 , wherein the adhesive comprises a pressure sensitive adhesive.

11 . The panel of claim 1 , wherein the non-woven veil has a thickness of from about 0.2 mm to about 0.5 mm.

12 . The panel of claim 1 , wherein the substrate is substantially free of punch holes, wheel abrasions, embossing or erosion.

13 . A coated non-woven veil comprising:
a non-woven veil comprising:
from about 20 wt. % to about 60 wt. % fibers; and
from about 40 wt. % to about 80 wt. % of a filler; and
a coating applied to the non-woven veil, the coating comprising: a binder; particles; and a carrier.

14 . The veil of claim 13 , comprising from about 110 dry g/m 2 to about 135 dry g/m 2 of the coating.

15 . The veil of claim 13 , wherein the carrier is an aqueous carrier.

16 . The veil of claim 13 , wherein the binder is selected from a natural polymer, a modified natural polymer, a synthetic polymer and a combination of two or more thereof.

17 . The veil of claim 13 , wherein the particles comprise a material selected from calcium carbonate, dolomite, titanium dioxide, barium sulfate, clay, mica, limestone, silica, talc, perlite, gypsum, wollastonite, calcite, aluminum trihydrate, zinc, a polymer, a pigment and a combination of two or more thereof.

18 . The veil of claim 17 , wherein the particles have a d 50 of from about 50 microns to about 300 microns.

19 . The coated non--woven veil of claim 13 , wherein the non-woven veil hasg an airflow resistance of greater than 45 mks rayls and the coated non-woven veil has an airflow resistance of about 300 mks rayls or less.

20 . An acoustical panel, comprising:
a substrate; a coated non-woven veil comprising:
a coating applied to a non-woven veil, the non-woven veil comprising:
from about 20 wt. % to about 60 wt. % fibers; and
from about 40 wt. % to about 80 wt. % of a filler; and

wherein the coating is present on the non-woven veil in an amount ranging from about 110 dry g/m 2 to about 135 dry g/m 2 .

Assignees

• Armstrong World Ind Inc

Inventors

• Kragness Eric D
• Wells Chris
• Ebert Oliver
• Winkler Alfred

Classifications

• B32B37/24

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title

• Y10T428/25

  Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles · CPC title

• E04B9/045 Primary

  being laminated · CPC title

• B32B2037/243

  Coating · CPC title

• B32B37/12

  characterised by using adhesives · CPC title